Flangeless air filter

ABSTRACT

An apparatus and method are provided for a flangeless air filter configured to be mounted onto a flat surface within an air intake system of an internal combustion engine. The flangeless air filter is comprised of a cone-shaped filter medium, retained between a base and a cap, that is fabricated to remove contaminants and particulate matter from an intake airstream. The base includes a pliable seal that forms an airtight connection between the flangeless air filter and the flat surface of the air intake system. A mounting bracket and fasteners may be used to attach the base to the flat surface, compressing the seal there between. In some embodiments, the mounting bracket may be incorporated into, and made a part of the base. A cap is disposed on a top of the flangeless air filter and configured to direct the intake airstream around the cap and toward the filter medium.

FIELD

The field of the present disclosure generally relates to filtrationdevices. More particularly, the field of the present disclosure relatesto an apparatus and a method for a flangeless air filter configured tobe mounted onto a flat surface within an air intake system of aninternal combustion engine.

BACKGROUND

An air filter designed to remove particulate matter from an airstreamgenerally is a device comprising fibrous materials. These fibrousmaterials may remove solid particulates such as dust, pollen, mold, andbacteria from the airstream. Air filters are used in applications whereair quality is important, notably in building ventilation systems andwith engines.

Air filters may be used in automobiles, trucks, tractors, locomotives,and other vehicles that use internal combustion engines. Air filters maybe used with gasoline engines, diesel engines, or other engines thatutilize fossil fuels or other combustible substances. Air filters may beused with engines in which combustion is intermittent, such asfour-stroke and two-stroke piston engines, as well as other types ofengines that take in air continuously so that a combustible substancemay be burned. For example, air filters may be used with some gasturbines. Filters may also be used with air compressors or in otherdevices that take in air.

Filters may be made from pleated paper, foam, cotton, spun fiberglass,or other known filter materials. Generally, the air filters used withinternal combustion engines and compressors tend to be comprised ofeither paper, foam, or cotton filters. Some filters use an oil bath. Airfilters for internal combustion engines prevent abrasive particulatematter from entering the cylinders of the engine, where it would causemechanical wear and oil contamination. In many fuel injected engines, aflat panel pleated paper filter element may be used. This filter isusually placed inside a plastic box connected to the throttle body withductwork. Vehicles that use carburetors or throttle body fuel injectiontypically use a cylindrical air filter positioned above the carburetoror throttle body.

SUMMARY

An apparatus and method are provided for a flangeless air filterconfigured to be mounted onto a flat surface within an air intake systemof an internal combustion engine. The flangeless air filter is comprisedof a base that includes a seal configured to contact the flat surfaceand connect an interior of the flangeless air filter with an air intakeduct of the internal combustion engine. The seal is comprised of apliable material amendable to being compressed so as to establish anairtight connection between the base and the flat surface. A cap isfixedly attached to a top of the flangeless air filter and configured todirect an intake airstream into the flangeless air filter. The cap iscomprised of a rigid material suitable for withstanding the temperatureand pressure within the air intake system. A filter medium is disposedbetween the base and the cap. The filter medium is configured to removecontaminants and particulate matter from the intake airstream enteringthe air intake duct. In some embodiments, the filter medium isconfigured to be treated with a filter oil composition so as to enhanceair cleaning properties of the filter medium. A wire support may beincorporated into the filter medium so as to provide additional strengthand durability to the flangeless air filter.

In an exemplary embodiment, a flangeless air filter configured to bemounted onto a flat surface within an air intake system of an internalcombustion engine comprises a base comprised of a seal that isconfigured to contact the flat surface and connect an interior of theflangeless air filter with an air intake duct of the internal combustionengine; a cap configured to direct an intake airstream into theflangeless air filter; and a filter medium disposed between the base andthe cap, the filter medium being configured to remove contaminants andparticulate matter from the intake airstream entering the air intakeduct.

In another exemplary embodiment, the cap is comprised of a rigidmaterial suitable for withstanding the temperature and pressure withinthe air intake system, the cap being fixedly attached to a top of theflangeless air filter. In another exemplary embodiment, the seal iscomprised of a pliable material amendable to being compressed so as toestablish an airtight connection between the base and the flat surface.In another exemplary embodiment, the base is molded onto and retains awire support and the filter medium.

In another exemplary embodiment, a mounting bracket is coupled with thebase, the mounting bracket being a generally ring-shaped membercomprised of an opening that receives a portion of the filter mediumadjacent to the base. In another exemplary embodiment, the openingincludes a diameter that is suitable to receive the largest diameter ofthe filter medium, such that the mounting bracket contacts an uppersurface of the base. In another exemplary embodiment, a multiplicity ofholes are disposed around the circumference of the mounting bracket andconfigured to receive hardware fasteners so as to couple the base withthe flat surface. In another exemplary embodiment, the mounting bracketis incorporated into, and made a part of, the base of the flangeless airfilter.

In another exemplary embodiment, the filter medium is configured to betreated with a filter oil composition so as to enhance air cleaningproperties of the filter medium. In another exemplary embodiment, a wiresupport is incorporated into the filter medium so as to provideadditional strength and durability to the flangeless air filter. Inanother exemplary embodiment, the wire support comprises a wire screenpositioned on an outer surface and a wire screen positioned on an innersurface of the filter medium. In another exemplary embodiment, the wirescreens are comprised of powder-coated aluminum screen wire that isco-pleated along with the filter medium so as to reinforce theflangeless air filter.

In an exemplary embodiment, a method for a flangeless air filter to bemounted onto a flat surface within an air intake system of an internalcombustion engine comprises configuring a base that is comprised of apliable seal to contact the flat surface and connect an interior of theflangeless air filter with an air intake duct of the internal combustionengine; attaching a cap fixedly to a top of the flangeless air filter todirect an intake airstream into the flangeless air filter; andfabricating a filter medium to remove contaminants and particulatematter from the intake airstream entering the air intake duct; retainingthe filter medium between the base and the cap; and coupling a mountingbracket with the base, such that the pliable seal may establish anairtight connection between the base and the flat surface.

In another exemplary embodiment, coupling is comprised of disposingholes around the circumference of the mounting bracket to receivehardware fasteners that are suitable to hold the pliable seal in contactwith the flat surface. In another exemplary embodiment, coupling furthercomprises incorporating the mounting bracket into the base.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings refer to embodiments of the present disclosure in which:

FIG. 1 illustrates an upper perspective view of an exemplary embodimentof a flangeless air filter comprising a cap that encloses a top portionof a filter medium;

FIG. 2 is a lower perspective view of the flangeless air filter of FIG.1, illustrating a base configured to be coupled with a flat mountingsurface within an air intake system of an internal combustion engine;

FIG. 3 illustrates an upper perspective view of an exemplary embodimentof a flangeless air filter coupled with a mounting bracket for fasteningthe flangeless air filter to an air intake system of an internalcombustion engine; and

FIG. 4 illustrates a lower perspective view of the flangeless air filterof FIG. 3. with exemplary hardware fasteners engaged with holes of themounting bracket.

While the present disclosure is subject to various modifications andalternative forms, specific embodiments thereof have been shown by wayof example in the drawings and will herein be described in detail. Theinvention should be understood to not be limited to the particular formsdisclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth inorder to provide a thorough understanding of the present disclosure. Itwill be apparent, however, to one of ordinary skill in the art that theinvention disclosed herein may be practiced without these specificdetails. In other instances, specific numeric references such as “firstfilter medium,” may be made. However, the specific numeric referenceshould not be interpreted as a literal sequential order but ratherinterpreted that the “first filter medium” is different than a “secondfilter medium.” Thus, the specific details set forth are merelyexemplary. The specific details may be varied from and still becontemplated to be within the spirit and scope of the presentdisclosure. The term “coupled” is defined as meaning connected eitherdirectly to the component or indirectly to the component through anothercomponent. Further, as used herein, the terms “about,” “approximately,”or “substantially” for any numerical values or ranges indicate asuitable dimensional tolerance that allows the part or collection ofcomponents to function for its intended purpose as described herein.

In general, the present disclosure describes an apparatus and a methodfor a flangeless air filter configured to be mounted onto a flat surfacewithin an air intake system of an internal combustion engine. Theflangeless air filter is comprised of a cone-shaped filter medium thatis retained between a base and a cap. The filter medium is fabricated toremove contaminants and particulate matter from an intake airstream. Insome embodiments, the filter medium may be configured to be treated witha filter oil composition so as to enhance air cleaning properties of thefilter medium. A wire support may be incorporated into the filter mediumto provide additional strength and durability to the flangeless airfilter. The base is comprised of a pliable seal that forms an airtightconnection between the flangeless air filter and the flat surface of theair intake system. A mounting bracket and fasteners may be coupled withthe flangeless air filter to attach the base to the flat surface andcompress the seal there between. A cap is disposed on a top of theflangeless air filter and configured to direct the intake airstreamaround the cap and toward the filter medium.

Although embodiments of the invention may be described and illustratedherein in terms of a cone-shaped air filter, it should be understoodthat embodiments of this invention are not limited to the exact shapeillustrated, but rather may include a wide variety of generally enclosedshapes, such as cylindrical, circular, oval, round, curved, conical, orany other closed perimeter shape, that provide a relatively largesurface area in a given volume of the filter. Moreover, embodiments asdescribed herein are not limited to use as internal combustion enginefilters, but rather may have applicability in other filtration systemsin which a large volume of air requires treatment.

FIG. 1 illustrates an upper perspective view of an exemplary embodimentof a flangeless air filter 100 configured for use within an air intakesystem of an internal combustion engine. It is contemplated that the airintake system may be either of a closed variety or an open intakesystem. The flangeless air filter 100 is comprised of a filter medium104 disposed between a base 108 and a cap 112. The flangeless air filter100 is configured to be coupled with an air intake duct comprising theair intake system, such that an intake airstream is directed around thecap 112 to an exterior of the filter medium 104, drawn through thefilter medium 104 into an interior 106 of the flangeless air filter 100,and drawn into the air intake duct to the internal combustion engine.The filter medium 104 is configured to remove contaminants andparticulate matter from the intake airstream that is drawn into the airintake duct. The filter medium 104 is a generally cone-shaped memberhaving a diameter that tapers as a function of distance from the base108 along the filter medium. The cap 112 serves to direct the intakeairstream around the top-most portion of the flangeless air filter andinto the filter medium 104. It is contemplated that the cap 112 may becomprised of a rigid material suitable for withstanding the temperatureand pressure encountered within the air intake system.

In the embodiment of the flangeless air filter 100 illustrated in FIGS.1-2, the base 108 has a diameter that is greater than the diameter ofthe cap 112. In some embodiments, however, the diameter of the base 108may be substantially equal to the diameter of the cap 108. It should beunderstood that the flangeless air filter 100 of the present disclosureis not limited to the exact shape illustrated in FIGS. 1-2, but rathermay include a wide variety of generally cylindrical, circular, oval,round, curved, or other closed perimeter shapes, that provide arelatively large surface area of the filter medium 104. Further, it willbe appreciated that the specific configuration of the flangeless airfilter 100 depends upon the particular make and model of the engine forwhich the flangeless air filter is to be utilized, and thus a widevariety of heights and diameters of the filter medium 104 may beincorporated into the flangeless air filter 100 without straying beyondthe scope of the present disclosure.

The base 108 generally is configured to support the flangeless airfilter 100 and provide an interface between the interior 106 of theflangeless air filter and the air intake duct of the internal combustionengine. Any of a variety of fasteners (not shown) may be used to affixthe filter medium 104 to the base 108. In some embodiments, the base 108may be molded to a wire support of the filter medium 104. In someembodiments, the base 108 may be crimped such that it folds onto andretains the wire support and the filter medium 104 of the flangeless airfilter 100. It will be appreciated by those skilled in the art thataffixing the filter medium 104 to the base 108 generally renders thefilter medium 104 irremovable from the flangeless air filter 100. Assuch, it is contemplated that a practitioner may periodically clean theflangeless air filter 100, as discussed herein below.

In an exemplary embodiment illustrated in FIGS. 3-4, a mounting bracket116 is coupled with the base 108. The mounting bracket 116 is agenerally ring-shaped member comprised of an opening 120 that receives aportion of the filter medium 104 adjacent to the base 108. As such, theopening 120 includes a diameter that is suitable to receive the largestdiameter of the filter medium 104, such that the mounting bracket 116 isplaced into contact with an upper surface 118 of the base 108, as bestshown in FIG. 1. A multiplicity of holes 124 may be disposed around thecircumference of the mounting bracket 116 and configured to couple thebase 108 with the air intake of the engine. In the illustratedembodiment of FIGS. 3-4, three of the holes 124 are disposed uniformlyaround the circumference of the mounting bracket 116 and are threaded soas to receive suitable hardware fasteners 128. The mounting bracket 116may be a separate component that is configured to cooperate with theflangeless air filter 100, as shown in FIGS. 3-4, or the mountingbracket 116 may be incorporated directly into the base 108 of theflangeless air filter 100. Further, in some embodiments, the positionsof the holes 124 on the mounting bracket 116 may be varied from thoseshown in FIGS. 3-4, and may depend upon the make and model, as well asthe specific configuration of the engine, for which the flangeless airfilter 100 is intended to be used.

As will be appreciated, the holes 124 and the hardware fasteners 128 areparticularly suitable for attaching the base 108 to a flat surface, suchas an interior mounting surface of an air intake system of the internalcombustion engine. A bottom of the base 108 preferably includes a seal132 that is disposed circumferentially around an opening 136 to theinterior 106 of the flangeless air filter 100. The seal 132 preferablyis comprised of a pliable material that is amenable to being compressedbetween base 108 and the interior mounting surface of the air intakesystem. It is contemplated that the interior mounting surface includesholes through which the fasteners 128 may be extended before beingthreadably engaged with the holes 124. When the fasteners 128 are thentightened into the holes 124, the seal 132 establishes an airtightconnection between the base 108 and the interior mounting surface,thereby forcing the airstream to pass through the filter medium 104before entering the engine. It should be understood, however, that theflangeless air filter 100 is not to be limited to being used with themounting bracket 116, the holes 124, or the fasteners 128, but ratherthe flangeless air filter 100 may be coupled with a wide variety of airintake systems by way of any of various mechanical fastening means,without deviating beyond the spirit and scope of the present disclosure.

The cap 112 may be affixed to the filter medium 104 by way of any of avariety of fasteners (not shown), or suitable adhesives. In someembodiments, the cap 112 may be molded onto the above-mentioned wiresupport and the filter medium 104. In some embodiments, the cap 112 maybe crimped around its peripheral edge such that it folds onto andretains the wire support and the filter medium 104 of the flangeless airfilter 100. Any of various fastening means may be practiced forattaching the filter medium 104 and the wire support to the cap 112,without limitation. Further, the cap 112 preferably is comprised of amaterial that is sufficiently hard to retain the filter medium 104 in adesired configuration and support the flangeless air filter 100 whencoupled to the air intake system of the engine.

In general, the filter medium 104 provides a surface area through whichto pass the intake airstream and entrap particulates and othercontaminates flowing with the intake airstream. The filter medium 104may be comprised of paper, foam, cotton, spun fiberglass, or other knownfilter materials, woven or non-woven materials, synthetic or natural, orany combination thereof. The filter medium 104 may be pleated, orotherwise shaped, or contoured so as to increase the surface area forpassing the intake airstream to be cleaned. The length of the filtermedium 104 in the circumferential direction may be longer than thecircular circumference of the flangeless air filter 100 generally, suchthat the surface area of the filter medium 104 is greater than theprofile surface area of the flangeless air filter.

As mentioned above, some embodiments of the flangeless air filter 100may be comprised of a wire support that is incorporated into the filtermedium 104. Incorporating the wire support into the filter medium 104provides additional strength and durability to the flangeless air filter100. For example, the filter medium 104 may be positioned between thewire support and one or more layers of a reinforcing material. The wiresupport may be comprised of wire screens positioned on an outer surfaceand an inner surface of the filter medium 104. In some embodiments, thefilter medium 104 may be comprised of 4 to 6 layers of cotton gauze thatare sandwiched between two epoxy-coated aluminum wire screens. It iscontemplated that the wire screens may be co-pleated along with thefilter medium 104 so as to reinforce the flangeless air filter 100.

Moreover, the cotton gauze may be advantageously treated with a suitablyformulated filter oil composition that causes tackiness throughoutmicroscopic strands comprising the filter medium 104. The nature of thecotton allows high volumes of airflow, and when combined with thetackiness of the filter oil composition creates a powerful filteringmedium which ensures a high degree of air filtration. Further detailsabout components comprising the filter medium 104, as well as detailsabout the filter oil composition, are disclosed in U.S. patentapplication Ser. No. 14/181,678, entitled “Air Box With IntegratedFilter Media,” filed on Feb. 16, 2014, and U.S. patent application Ser.No. 14/701,163, entitled “Filter Oil Formulation,” filed on Apr. 30,2015, the entirety of each of which is incorporated herein by reference.

It is contemplated that a practitioner of the flangeless air filter 100may periodically clean the filter medium 104 rather than discarding theentire flangeless air filter, as is done with conventional air filters.In one embodiment, a cleaning method may be comprised of accessing theflangeless air filter 100 within the air intake system and then removingthe fasteners 128 from the holes 124 to loosen and release the mountingbracket 116. The flangeless air filter 100 may then be removed from theair intake system. The practitioner may clean the flangeless air filter100 by inserting a water hose through the opening 136 into the interior106 and then spraying water so as to flush contaminants from the filtermedium 104. In some embodiments, the method for cleaning the flangelessair filter 100 may be comprised of utilizing a high pressure air hose inlieu of the water hose. In some embodiments, the method for cleaning theflangeless air filter 100 may be comprised of spraying water onto theexterior of the filter medium 104, such that the water and contaminantsare flushed directly from the exterior of the filter medium 104. It iscontemplated that any water and contaminants that are forced through thefilter medium 104 may exit the interior 106 through the opening 136.Other cleaning methods will be apparent to those skilled in the artwithout deviating from the spirit and scope of the present disclosure.

While the invention has been described in terms of particular variationsand illustrative figures, those of ordinary skill in the art willrecognize that the invention is not limited to the variations or figuresdescribed. In addition, where methods and steps described above indicatecertain events occurring in certain order, those of ordinary skill inthe art will recognize that the ordering of certain steps may bemodified and that such modifications are in accordance with thevariations of the invention. Additionally, certain of the steps may beperformed concurrently in a parallel process when possible, as well asperformed sequentially as described above. To the extent there arevariations of the invention, which are within the spirit of thedisclosure or equivalent to the inventions found in the claims, it isthe intent that this patent will cover those variations as well.Therefore, the present disclosure is to be understood as not limited bythe specific embodiments described herein, but only by scope of theappended claims.

What is claimed is:
 1. A flangeless air filter configured to be mountedonto a flat surface within an air intake system of an internalcombustion engine, comprising: a base comprised of a seal that isconfigured to contact the flat surface and connect an interior of theflangeless air filter with an air intake duct of the internal combustionengine; a cap configured to direct an intake airstream into theflangeless air filter; and a filter medium disposed between the base andthe cap, the filter medium being configured to remove contaminants andparticulate matter from the intake airstream entering the air intakeduct, wherein the seal is comprised of a pliable material amendable tobeing compressed so as to establish an airtight connection between thebase and the flat surface, wherein an externally facing surface of theseal is a flat, ridgeless surface configured to establish the airtightconnection and wherein the flat, ridgeless surface spans from aninterior opening of the base to an exterior edge of the base, wherein amounting bracket is coupled with the base and includes a plurality ofprotrusions configured to enable coupling with the flat surface, whereinthe protrusions extend outward relative to the interior opening of thebase, the mounting bracket being a generally ring-shaped membercomprised of an opening that receives a portion of the filter mediumadjacent to the base.
 2. The air filter of claim 1, wherein the cap iscomprised of a rigid material suitable for withstanding the temperatureand pressure within the air intake system, the cap being fixedlyattached to a top of the flangeless air filter.
 3. The air filter ofclaim 1, wherein the base is molded onto and retains a wire support andthe filter medium.
 4. The air filter of claim 1, wherein the openingincludes a diameter that is suitable to receive the largest diameter ofthe filter medium, such that the mounting bracket contacts an uppersurface of the base.
 5. The air filter of claim 1, wherein amultiplicity of holes are disposed around the circumference of themounting bracket and configured to receive hardware fasteners so as tocouple the base with the flat surface.
 6. The air filter of claim 1,wherein the mounting bracket is incorporated into, and made a part of,the base of the flangeless air filter.
 7. The air filter of claim 1,wherein the filter medium is configured to be treated with a filter oilcomposition so as to enhance air cleaning properties of the filtermedium.
 8. The air filter of claim 1, wherein a wire support isincorporated into the filter medium so as to provide additional strengthand durability to the flangeless air filter.
 9. The air filter of claim8, wherein the wire support is comprised of a wire screen positioned onan outer surface and a wire screen positioned on an inner surface of thefilter medium.
 10. The air filter of claim 9, wherein the wire screen iscomprised of powder-coated aluminum screen wire that is co-pleated alongwith the filter medium so as to reinforce the flangeless air filter. 11.A method for a flangeless air filter to be mounted onto a flat surfacewithin an air intake system of an internal combustion engine,comprising: configuring a base that is comprised of a pliable seal tocontact the flat surface and connect an interior of the flangeless airfilter with an air intake duct of the internal combustion engine;attaching a cap fixedly to a top of the flangeless air filter to directan intake airstream into the flangeless air filter; fabricating a filtermedium to remove contaminants and particulate matter from the intakeairstream entering the air intake duct; retaining the filter mediumbetween the base and the cap; and coupling a mounting bracket with thebase, such that the pliable seal is configured to establish an airtightconnection between the base and the flat surface, wherein an externallyfacing surface of the seal is a flat, ridgeless surface configured toestablish the airtight connection and wherein the flat, ridgelesssurface spans from an interior opening of the base to an exterior edgeof the base, wherein a mounting bracket is coupled with the base andincludes a plurality of protrusions configured to enable coupling withthe flat surface, wherein the protrusions extend outward relative to theinterior opening of the base, the mounting bracket being a generallyring-shaped member comprised of an opening that receives a portion ofthe filter medium adjacent to the base.
 12. The method of claim 11,wherein coupling is comprised of disposing holes around thecircumference of the mounting bracket to receive hardware fasteners thatare suitable to hold the pliable seal in contact with the flat surface.13. The method of claim 12, wherein coupling further comprisesincorporating the mounting bracket into the base.